Pallet for bagged materials

ABSTRACT

The present invention generally relates to pallet structures for supporting a flexible intermediate bulk container with interchangeable, recyclable and replaceable components. Where the pallet structure is composed of a substantially planar base that may be fabricated from a material such as a sheet of corrugated plastic; runners that may be composed of polyvinyl chloride (PVC); straps and strap fasteners to secure the runners to upper the upper surface of the base so that a flexible intermediate bulk container placed on the pallet structure conforms to a the shape of the runners.

CROSS REFERENCE TO RELATED APPLICATION

This application claims priority from U.S. Provisional Application Ser. No. 62/063,621, filed Oct. 14, 2014; the disclosure of which is incorporated herein by reference.

FIELD OF THE INVENTION

The current invention relates generally to apparatus, systems, and methods for transporting bagged materials. More particularly, the apparatus, systems, and methods relate to storing and/or transporting bagged material on pallets. Specifically, the apparatus, systems, and methods provide for pallet structures with interchangeable, recyclable and, replaceable components for supporting a flexible intermediate bulk container or bag.

BACKGROUND OF THE INVENTION

Pallets are typically used to support a load, allowing the load to be lifted and transported by a lift vehicle such as a forklift. Pallets typically have a platform upon which a load rests and a base having channels below or internal to the base that are adapted to receive the fork tines of a forklift. These pallets are typically constructed from wood or plastic, and while these pallets are generally reusable, they are subject to breakage. Disadvantages to using platform-type pallets involve the cost of producing the pallet, inability to replace components, weight, and cost and inconvenience of shipping the pallet back from its destination so it may be reused. The shipping costs are even more significant for relatively heavier pallets (e.g., wood pallets).

In addition, a load resting upon a typical pallet needs precisely balanced because typical pallets have a flat surface without any structure to stabilize a load. Loads such as a flexible intermediate hulk container or a bag are not rigid by design and often contain loose material; which is prone to shifting. This shifting, combined with the lack of rigidity, makes it difficult to keep a load consisting, of a flexible intermediate bulk container or bag balanced and stable on the flat surface of a typical pallet. If a load consisting of a flexible intermediate bulk container becomes unbalanced and topples, there is a safety concern due to the risk of injury. What is needed is a better pallet.

SUMMARY OF THE INVENTION

One aspect of an embodiment of the invention includes a pallet far flexible material. The pallet includes a base, runners, and connector parts. The base has a gene ally planer upper surface and a general planer lower surface. Two or more runners are located on the upper surface of the base and extending upward from the upper surface of the base. In some configurations, the runners have a cross-section that is semi-circular or at least 50 percent annular in shape. In other configurations the runners may have other suitable cross-sections such as rectangular cross-sections, triangle cross-sections, partially rectangular and partially rounded cross-sections, or have another suitable cross-section. The connector parts attach the runners to the base. The runners are adapted to allow a bag of material, in some instances, to be placed on top of the two or more runners so that the bag material at least partially conforms to the shape of the two or more runners. In some configurations, the two or more runners are adapted to receive the fork tines of a forklift vehicle to allow the pallet to be lifted by the forklift vehicle.

In another configuration, the pallet structure is composed of a base that may be fabricated from a material such as a sheet of corrugated plastic, and the runners may be composed of any rigid material including polyvinyl chloride (PVC). The runners need not be smooth and may have a texture bestowed on them during or after fabrication. The base may be planar and may have reinforcements such as longitudinal ribs, reinforcing strips, or a perimeter structure (e.g. a rigid frame). The base of the pallet structure may have a plurality of perforations or attachment components (e.g. a loop, ring, or hook attached to the base). The attachment components allow straps to suitably secure at least one runner to the base. For example, an attachment component (e.g. strap) may pass through slots/perforations in the base and wrap around a runner to secure the runner to the base. A linking part may be locked onto the strap to resist loosening to secure the strap in place about the runner.

In an example embodiment, the runners are placed upon the upper surface of the base to add stabilizing structure to a pallet with a load that may be a flexible intermediate bulk container. A flexible intermediate bulk container placed upon the pallet may form around the runners, creating a temporary arrangement. This temporary arrangement increases the stability of a flexible intermediate bulk container resting upon the pallet. The runners also serve to help guard against shifting of a flexible load (e intermediate bulk container) resting on a pallet.

The use of removable components enables the base, a runner, a connecting part, or a linking part that is damaged, worn out, or otherwise unusable to be simply removed and replaced. This allows for quick and easy replacement of any of the runners, the straps, or the base. This reduces downtime caused by a damaged pallet, extends the useful life of a pallet, and reduces pallet replacement cost by allowing the replacement of individual components. In some configurations, the pallet may be composed of mostly plastic components. The use of mostly plastic components allows the pallet to be lighter, water resistant, and substantially recyclable. Components of the pallet may also be made out of other materials such as aluminum, carbon fiber, wood, and other lightweight and rigid materials.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is an example top view of one embodiment of a base of a pallet for bagged material without runners attached that has slot securing parts.

FIG. 1B is an example top view of one embodiment of a base of a pallet for bagged material without runners attached that has D-ring securing parts.

FIG. 2 is an example a top view of an embodiment of a pallet with runners attached.

FIG. 3 is an example an elevation view of a side of the pallet of FIG. 2.

FIG. 4 is an example illustration of the pallet of FIG. 2 used in one configuration with a single bag of flexible material.

FIG. 5 is an example illustration of the pallet of FIG. 2 used in another configuration between two bags of flexible material.

DETAILED DESCRIPTION OF THE DRAWINGS

As shown in FIGS. 1A, 2 and 3, one embodiment of the pallet or pallet structure 2 includes a base 10. The base 10 may include a plurality of securing parts 12. FIGS. 1A, 2 and 3 illustrate the securing parts 12 as openings (slots, holes, etc.) in the base 10; however, in other embodiments the securing parts 12 may be other types of securing components as describe below. The securing parts 12 in combination with connecting parts 30 secure a pair of runners 24 to the base 10. In some configurations, one or more of the connecting parts 30 may have at least one linking part 32. In general, the securing parts 12 are what secure the connecting part 30 to the base 10.

As shown in FIG. 1, the base 10 can be planar and may be constructed from a material which is lightweight, rigid, and of sufficient strength to function as the base Examples of such materials include aluminum, carbon fiber, wood, suitable plastics, and suitable plastic structures such as corrugated plastic. The term “rigid” does not mean absolutely rigid but includes a base having some flexibility especially when subjected to the weight of one or more flexible bulk containers (discuss later) placed upon the pallet structure 2 and the base 10.

The plurality of securing parts may be slots 12 formed in the base 10. Alternative securing parts may be hooks, latches, rings, a plurality of D-rings, each fastened to the base 10 by a strap or other suitable securing parts. For example, FIG. 1B illustrates a base 10 with securing parts that are four pairs of D-rings 15 attached to the base 10 with screws 17.

The at least one connecting pan 30 may be a strap, tie, wire, rope, steel-reinforced tape, a belt or other suitable connecting parts.

In one embodiment, shown in FIG. 1A, the plurality of securing parts 12 may be slots 12. The slots 12 in base 10 may be of any suitable shape. In one embodiment, the slots 12 may be elongated shapes. For example, the elongated shapes may be shaped to allow straps to pass through slots 12, may be rounded to allow rope material to pass through them, or may be another suitable shape. The base 10 may be perforated with a plurality of slots 12, which may be located at suitable locations.

As shown in FIGS. 2-3, each of a plurality of rigid support members or runners 22, 24 may have any suitable cross-sectional configuration adapted to accommodate or house a fork tine of a forklift vehicle, and to stably sit upon a flat surface. While the runners 22, 24 are described as “rigid’, in some embodiments they are not absolutely rigid but may have some flexibility. Each runner 22, 24 may have similar or different cross sections. Runners 22, 24 may be positioned to facilitate the acceptance of a plurality of fork tines of a forklift vehicle. Runners 22, 24 may be fabricated from a material suitable to tolerate forces, conditions, and stresses encountered during the use of the pallet 2. The runners 22, 24 may have a texture bestowed upon them during or after fabrication. Each runner 22, 24 may be molded with a texture; a textured material may be adhered to each runner 22, 24; or a textured coating may be applied to each runner 22, 24. For example, texture may have closely spaced groove patterns cut into runners 22, 24 especially on an upper surface onto which a flexible bag may be placed. The texture creates a higher coefficient of friction than a non-textured runner to help prevent the flexible bag from sliding with respect to runners 22, 24. Each runner 22, 24 may be removably attached to the base 10 by at least one connecting part 30 and linking part 32. Connecting parts 30 may wrap around one or more runners 22, 24 or may pass through one or more runners 22, 24 as understood by a person of ordinary skill in the art. Each runner 22, 24 may be provided, upon the upper surface 14 of the base 10 of the pallet structure 2.

In one embodiment, the rigid support members or runners 22, 24 may include longitudinally bisected rigid tubes or pipes, fabricated from suitable materials, examples being′ tubes or pipes composed of Acrylonitrile butadiene styrene (ABS) or polyvinylchloride (PVC), or paper material (e.g. a large paper roll such as a core from a large roll of bulk material).

The connecting part or strap 30 may have a linking part 32, which may be integrated or removably attached. The linking part 32 may be a hook-and-loop type fastener (one example of which is Velcro®), buckle, snap, clamp, stitching, or any other suitable part. The linking part 32 allows the strap 30 to attach different portions of itself together. The linking part 32 may also allow the strap 30 to be attached to, itself, another strap 30, the base 10, a runner 22, 24, or another suitable component of pallet structure 2.

In one embodiment, shown in FIGS. 1A and 2, slots 12 may be arranged in pairs approximately parallel to runners 22, 24 to facilitate the threading of a linking pan 32 and related strap 30 through a slot 12 from either the upper surface 14 to the lower surface 16 or from the lower surface 16 to the upper surface 14.

The securing of a runner 22, 24 may begin with a portion of the strap 30 being threaded from the upper surface 14 to the lower surface 16. The strap 30 may then pass along the lower surface 16. After which, the strap 30 may pass over a runner 22, 24. The strap 30 may then be attached to another section of the same strap 30 by a linking part 32 to secure the runner 22, 24 to the upper surface 14 of the base 10.

In an additional embodiment, the securing of a runner 22, 24 may begin with a portion, of the strap 30 being threaded through a slot 12 from the upper surface 14 to the lower surface 16. The strap 30 may then pass along the lower surface 16. The strap 30 may then be threaded upward through a second slot 12 toward the upper surface 14, after which the strap 30 may pass over a runner 22, 24. The strap 30 may then be threaded downward through another slot 12. The strap 30 may again pass along the lower surface 16 to a slot 12 where the strap 30 may again be threaded upward through the same slot 12 toward the upper surface 14. The strap 30 may then pass over the same runner 22, 24 a second time. One end of the strap 30 may be attached to another section of the strap 30 by the linking part 32 to secure the runner 22, 24 to the upper surface 14 of the base 10 and to ensure the strap 30 will not become loose.

As shown in FIG. 4, one or more flexible intermediate bulk containers (otherwise known as a bag or article container) 40 may be placed upon pallet 2. Bag 40 may be formed of one or multiple panels fastened together by stitching or by some other suitable fastener used to secure seams. The bag may have a bottom panel. Attached to the bottom panel may be one or more side panels. Attached to the one or more side panels may be at least one top panel. The bag may also include carrying loops or handles attached in suitable manner at a suitable location, for example, the loops may be stitched to the one or more side panels. A plurality of bags may be used as a system 50.

As illustrated, a lower portion of the bag 40 is flexible and conforms its shape to the runners 22, 24 and base 10. A central lower portion 60 of the hag 40 may even be flexible enough to touch base 10 while outer portions 62, 64 of bag 40 may partially conform to the shape of the runners 22, 24, as illustrated, and in some configurations may conform to the shape of the runners 22, 24 in addition to touching the base 10. The overall configuration of the pallet structure 2 with runners 22, 24 may provide for a pallet structure 2 with increased water resistance to further prevent the bag 40 from sliding upon the pallet structure 2.

When the pallet structure 2, along with the article container 40, are lifted and/or transported, the fork tines of a forklift truck may be inserted, into runners 22, 24. This enables the bag/container 40 to be lifted and transported. The system 50 of a flexible intermediate bulk container 40 and pallet 2 may be used to stack a plurality of containers 40. As shown in FIG. 5, the system of a flexible intermediate bulk container 40 and pallet 2 may be placed upon a second flexible intermediate bulk container 41 to enable stable stacking of a plurality of containers 40. Similar to FIG. 4, a flexible intermediate hulk container (bag) 40 is flexible and conforms its shape to the runners 22, 24 and base 10. Again the central lower portion 60 of the bag 40 may even be flexible enough to touch base 10 while outer portions 62, 64 of bag 40 may partially conform to the shape of the runners 22, 24, as illustrated. Additionally, the weight of upper bag 40 may be heavy enough to cause the base 10 to partially deflect, as illustrated, to allow an upper portion 66 of lower bag 41 become curved to conform its shape to the deflected base 10. When bags 40, 41 conform to the shape of the pallet structures 2, additional gripping surfaces and shapes are created to further prevent bags 40, 41 from shifting or sliding with respect to the pallet structures 2 to prevent them from sliding or falling off the pallet structures 2 whether in storage or while being moved upon a pallet structure 2. In some configurations, smaller bags of material may be placed between runners 22, 24 which may then act as barricades to prevent smaller bags from sliding from pallet structure 2. For example, 40-50 pounds or less of fertilizer, topsoil, mulch, and the like may be placed between runners 22, 24, in some configurations of system 50.

In other configurations, more than two bags may be stacked using system 50. For example, a flexible intermediate bulk container may stacked between two other flexible intermediate bulk containers with a pallet structure 2 between each pair of stacked flexible intermediate bulk containers.

In accordance with the provisions of the patent statutes, the subject invention has been described in what is considered to represent its preferred embodiment. However, it should be understood that the invention can be practiced otherwise than as specifically illustrated and described without departing from its spirit, or scope. 

What is claimed is:
 1. A pallet for bagged material comprising: a base having an upper surface, a lower surface, a thickness, and a plurality of securing parts; a plurality of runners on the upper surface of the base, the plurality of runners adapted to accommodate the fork tines of a forklift vehicle; at least one connecting part having at least one elongated component; and at least one securing component attached to the at least one elongated component, the at least one connecting part coupled with at least one securing part to secure the plurality of runners to the base.
 2. The pallet for bagged material of claim 1, wherein the at least one securing part is a pair of slots extending the thickness of said base.
 3. The pallet for bagged material of claim 1, wherein said at least one connecting part is one or more of the group of a strap, a wire, a belt, and a tie.
 4. The pallet for bagged materials of claim 1, wherein at one of the connecting parts is wrapped at least partially around at least one runner.
 5. The pallet for bagged material of claim 1, wherein at one of the connecting part passes through at least one runner.
 6. The pallet for bagged material of claim 1, wherein said base, said plurality of runners, and said at least one connecting part are each individually removable in a nondestructive manner.
 7. The pallet for bagged material of claim 1, wherein said base is substantially planar.
 8. The pallet for bagged material of claim 1, wherein said plurality of runners are composed of one or more of the group of: paper, cardboard, Acrylonitrile butadiene styrene, and polyvinylchloride.
 9. The pallet for bagged material of claim 1, wherein said plurality of runners are of a semi-circular construction.
 10. The pallet for bagged material of claim 1, wherein said securing component is a hook-and-loop type fastener.
 11. A system for storing bagged material comprising: a pallet structure including, a base having an upper surface, a lower surface, a thickness, and a plurality of securing parts; a plurality of runners located on the upper surface of the base, the plurality of runners adapted to accommodate the fork tines of a forklift vehicle to allow the pallet structure to be lifted by the forklift vehicle; at least one connecting part having at least one elongated component, a securing component attached to the at least one elongated component, the at least one connecting part coupled with the plurality of securing parts to secure the plurality of runners to the base; and wherein the system provides for a first flexible bag being located upon a supporting surface, wherein the pallet structure is adapted to be located upon the top of the first bag, wherein the pallet structure is adapted to provide for a second bag being located upon the pallet structure with a bottom portion of the second bag partially conformed to the shape of the plurality of runners and with the bottom portion of the bag in at least partial contact with the base of said pallet structure.
 12. The system for transporting bagged materials of claim 11, wherein said plurality of runners are rigid thermoplastic tubes or pipes.
 13. The system for transporting bagged materials of claim 11, wherein at least one of the group of: said base, said plurality of runners, and said connecting, part are replaceable parts adapted to be removed from the pallet structure in a nondestructive manner.
 14. A pallet for flexible material comprising: a base with a generally planer upper surface and a general planer lower surface; two or more runners located on the upper surface of the base and extending upward from the upper surface of the base; connector parts adapted to attach the two or more runners to the base; and wherein the two or more runners and are adapted to allow a bag of material to be placed on top of the two or more runners so that the bag of material at least partial conforms to the shape of the two or more runners.
 15. The pallet of claim 14, wherein the two or more runners are adapted to receive the fork tines of a forklift vehicle to allow the pallet to be lifted by the forklift vehicle.
 16. The pallet of claim 14, wherein the two or more runners further comprise: a cross-section that is at least 50 percent annular in shape.
 17. The pallet of claim 14, wherein the connector parts further comprise: a plurality of straps, wherein the base thither comprises: a plurality of pairs of elongated slots passing from the planar upper surface to the planer lower surface of the base, wherein the straps pass through pairs of elongate slots to wrap around the runners and to wrap around material between pairs of elongated slots to attach the two or more runners to the base.
 18. The pallet of claim 17, further wherein each of the straps wrap around the runners and the material between adjacent donated slots at least two times.
 19. The pallet of claim 14, wherein the two or more runners have a rough texture on an outer surface of the two or more runners adapted to provide a higher coefficient of friction than if the two or more runners did not have the rough texture.
 20. The pallet of claim 18, wherein the base is generally rigid but having some flexibility. 